Neptronic WP440L Series Manual

Series L Standard System Manual w 150S option - 220414 - Josiah.docx
Reverse Osmosis Systems
WP440L Series
Installation Instructions and User Manual
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I-ROC150S
Controller

WP440L-Series Reverse Osmosis System
Installation Instructions and User Manual
www.neptronic.com
Page | - 2 -
Foreword
Neptronic Company Overview
Founded in 1976, we’re a private corporation that designs, manufactures and distributes products for the HVAC industry.
Our product line includes intelligent controllers, electronic actuators, actuated valves, humidifiers and electric heaters.
Our products are designed and manufactured by over 250 dedicated employees in our 7,500 m2 (80,000 ft2) state-of-the-
art facility located in Montreal, Canada. Using a vertical integration model, our entire manufacturing chain is under one roof,
from software and hardware development to SMT circuit board assembly, to sheet metal fabrication, to product testing,
ensuring that our products are engineered to last.
We currently hold several national and international patents and with our continued commitment to research and
development, we provide innovative products and technologies for the ever-evolving challenges of the HVAC industry.
Exporting over 70% of our sales, we have an exclusive distribution network around the globe that provides comprehensive
solutions to our worldwide customers.
About the Manual
These installation and operation instructions have been developed to facilitate the installation of the Reverse Osmosis for
the L-Series humidifiers.
•The strict application of these instructions will ensure the conformity of your installation and operation as per
the manufacturer's recommendations.
•The application of these instructions is one of the conditions for the application of the warranty.
•The application of these instructions does not ensure, at any time conformity to procedures, regulation or local
codes, regarding electric installation and connection to local water supply.
This product has been declared to conform to the applicable Canadian and American safety standards and directives and
bear the ETL (c) & (us) mark. The Certificate for ETL is available, upon request to the manufacturer.
2022©: All rights reserved. This document cannot be reproduced totally or partially by any means whether, electronic,
mechanical, photocopy, recording or other, without prior written authorization of Neptronic.
Electricity
All work concerned with electrical installation MUST only be performed by skilled and qualified
technical personnel, such as an electrician or a technician with appropriate training. The customer is
always responsible for ensuring the suitability of the technical personnel.
Please observe the local regulations concerning the provision of electrical installations.
Correct Use
Neptronic systems and its products are designed only for humidification use. Any other application is not considered
appropriate for the intended purpose. The manufacturer cannot be made liable for any damage resulting from incorrect use.
General Warranty
This product is subject to the terms and conditions described at http://www.neptronic.com/Sales-Conditions.aspx.

WP440L-Series Reverse Osmosis System
Installation Instructions and User Manual
www.neptronic.com
Page | - 3 -
Contents
RO System Design Specifications .......................................................................................................................................... 5
Design Assumptions ............................................................................................................................................................ 6
Design Notes ....................................................................................................................................................................... 6
General Information and Safety .............................................................................................................................................. 6
System Installation .................................................................................................................................................................. 7
Plumbing ................................................................................................................................................................................. 8
Feed Water Connection:...................................................................................................................................................... 8
Concentrate/Reject Connection........................................................................................................................................... 9
Permeate/Product Water Connection.................................................................................................................................. 9
Product Water Storage Tank Level Float Installation............................................................................................................ 10
Electrical Connections........................................................................................................................................................... 11
I-ROC150S RO System Controller Installation and Setup.................................................................................................... 12
Introduction ........................................................................................................................................................................ 12
Specifications..................................................................................................................................................................... 12
Relay Outputs .................................................................................................................................................................... 12
Power Wiring ..................................................................................................................................................................... 12
I/O Expander Board........................................................................................................................................................... 14
System Operation ................................................................................................................................................................. 20
I-ROC150S RO System Controller Operation ................................................................................................................... 20
General Operation ......................................................................................................................................................... 20
Front Panel Controls and Indicator ................................................................................................................................ 20
Operating Status Messages .............................................................................................................................................. 21
TDS / Conductivity ......................................................................................................................................................... 21
Operating Hours............................................................................................................................................................. 21
Temperature .................................................................................................................................................................. 21
Warning Messages ........................................................................................................................................................ 21
Tank Full Operation ....................................................................................................................................................... 21
Tank Full Restart............................................................................................................................................................ 22
Tank Full Override ......................................................................................................................................................... 22
Pressure Fault................................................................................................................................................................ 22
Auto Reset ..................................................................................................................................................................... 22
Alarm Silence ................................................................................................................................................................. 22
Pretreat .......................................................................................................................................................................... 22
Membrane Flush................................................................................................................................................................ 23
Flush Mode .................................................................................................................................................................... 23
High TDS / Conductivity Warning/Alarm........................................................................................................................ 23
Operating Hours Exceeded............................................................................................................................................ 23

WP440L-Series Reverse Osmosis System
Installation Instructions and User Manual
www.neptronic.com
Page | - 4 -
I/O Expander .................................................................................................................................................................. 24
Auxiliary Output.............................................................................................................................................................. 24
Tank Low........................................................................................................................................................................ 24
Boost Pump Output........................................................................................................................................................ 24
Divert Output .................................................................................................................................................................. 24
Alarm Output.................................................................................................................................................................. 24
ADJUSTMENTS ................................................................................................................................................................ 24
TDS / Conductivity Calibration....................................................................................................................................... 24
Display Adjustment ........................................................................................................................................................ 24
Initial System Start-Up....................................................................................................................................................... 25
Operating DO’s & DON’Ts................................................................................................................................................. 26
System Automation ........................................................................................................................................................... 26
System Shut-Down............................................................................................................................................................ 27
System Monitoring and Record Keeping ........................................................................................................................... 27
Data Log ............................................................................................................................................................................ 28
Troubleshooting .................................................................................................................................................................... 30
General Troubleshooting ................................................................................................................................................... 30
System Controller Troubleshooting – I-ROC150S ............................................................................................................ 31
Pump Troubleshooting (for Systems with Procon Pumps) ............................................................................................ 32
System Maintenance............................................................................................................................................................. 34
Sediment Pre-Filter Cartridge............................................................................................................................................ 34
When to Change Sediment Prefilter Cartridge .............................................................................................................. 34
Changing Cartridge Filters ............................................................................................................................................. 34
Membrane Cleaning .......................................................................................................................................................... 34
When to Clean Membranes ........................................................................................................................................... 34
Common Foulants and Their Associated Symptoms .................................................................................................... 35
Cleaning Sequence........................................................................................................................................................ 35
Cleaning Procedure Using Membrane Cleaning Cartridges.......................................................................................... 35
Membrane Replacement ................................................................................................................................................... 35
Low Pressure Switch Adjustment ...................................................................................................................................... 36
Pump Maintenance (for systems with Sta-Rite Pump)...................................................................................................... 37
Shut Down and Storage ........................................................................................................................................................ 38
Membrane Storage (outside of RO system)...................................................................................................................... 38
RO System Storage and Biocidal Protection..................................................................................................................... 38
Disinfection and Sterilization of RO Elements................................................................................................................... 39
Component Identification- Standard Features up to WP4406L........................................................................................ 39
Component Identification- Standard Features for WP440XL ............................................................................................ 43
General Arrangement of Systems with Procon Pump....................................................................................................... 44
General Arrangement of Systems with Sta-Rite Pump ..................................................................................................... 44
Parts & Instrumentation Drawing (P&ID) ........................................................................................................................... 45

WP440L-Series Reverse Osmosis System
Installation Instructions and User Manual
www.neptronic.com
Page | - 5 -
Replacement Parts and Consumables ................................................................................................................................. 46
Product Warranty .................................................................................................................................................................... 1
RO System Design Specifications
Table 1 - RO System Design Specifications
Model
Design Conditions
Limits*
Line Sizes (in.)
Pump model and HP
Permeate Flow Conc.
Flow to
Drain
(GPM)
Design
Recycle
Flow
(GPM)
Design
Recovery
(%)
Max.
Recovery*
(%)
Max.
Recycle
Flow*
(GPM)
Inlet Perm. Conc.
Design
Pump
Flow
(GPM)
Pump Model No. Motor
Model
Motor
HP
Full Load
Amps
(FLA)@
indicated
voltage
GPD GPM
WP4401L-116
1,800
1.2
4.3
0
25
60
3.4
0.75
0.5
0.5
5.5
114E330F11XX
P-MG573
1
16
WP4401L-216
1,800
1.2
4.3
0
25
60
3.4
0.75
0.5
0.5
5.5
114E330F11XX
P-MG573
1
8
WP4402L-116
3,000
2.2
2.6
0.8
45
60
1.8
0.75
0.5
0.5
5.5
114E330F11XX
P-MG573
1
16
WP4402L-216
3,000
2.2
2.6
0.8
45
60
1.8
0.75
0.5
0.5
5.5
114E330F11XX
P-MG573
1
8
WP4403L-216
5,200
3.5
3.5
1.0
50
60
2.2
0.75
0.5
0.5
8
HPS20H
W/PUMP
3
17
WP4403L-236
5,200
3.5
3.5
1.0
50
60
2.2
0.75
0.5
0.5
8
HPS20H3
W/PUMP
3
10
WP4403L-436
5,200
3.5
3.5
1.0
50
60
2.2
0.75
0.5
0.5
8
HPS20H3
W/PUMP
3
5
WP4404L-216
6,500
4.5
3.0
1.0
55
60
2.5
0.75
0.5
0.5
9
HPS20H
W/PUMP
3
17
WP4404L-236
6,500
4.5
3.0
1.0
55
60
2.5
0.75
0.5
0.5
9
HPS20H3
W/PUMP
3
10
WP4404L-436
6,500
4.5
3.0
1.0
55
60
2.5
0.75
0.5
0.5
9
HPS20H3
W/PUMP
3
5
WP4405L-216
8,500
5.5
4.0
1.5
60
75
3.5
0.75
0.5
0.5
11
HPS20H
W/PUMP
3
17
WP4405L-236
8,500
5.5
4.0
1.5
60
75
3.5
0.75
0.5
0.5
11
HPS20H3
W/PUMP
3
10
WP4405L-436
8,500
5.5
4.0
1.5
60
75
3.5
0.75
0.5
0.5
11
HPS20H3
W/PUMP
3
5
WP4406L-216
10,000
6.6
4.0
1.5
60
75
3.5
0.75
0.5
0.5
12
HPS20H
W/PUMP
3
17
WP4406L-236
10,000
6.6
4.0
1.5
60
75
3.5
0.75
0.5
0.5
12
HPS20H3
W/PUMP
3
10
WP4406L-436
10,000
6.6
4.0
1.5
60
75
3.5
0.75
0.5
0.5
12
HPS20H3
W/PUMP
3
5
WP440XL-216
17,300
12
4.5
2.0
65
75
3.0
0.75
0.75
0.5
17.5
HPS20H
W/PUMP
3
17
WP440XL-236
17,300
12
4.5
2.0
65
75
3.0
0.75
0.75
0.5
17.5
HPS20H3
W/PUMP
3
10
WP440XL-436
17,300
12
4.5
2.0
65
75
3.0
0.75
0.75
0.5
17.5
HPS20H3
W/PUMP
3
5
WP44012-216
19,000
13
4.5
2.0
65
75
3.0
0.75
0.75
0.5
18.5
HPS20H3-D1MS3
W/PUMP
3
10
WP44012-236
19,000
13
4.5
2.0
65
75
3.0
0.75
0.75
0.5
18.5
HPS20H3
W/PUMP
3
10
WP44012-436
19,000
13
4.5
2.0
65
75
3.0
0.75
0.75
0.5
18.5
HPS20H3
W/PUMP
3
5
*Water must be softened or have antiscalant injection. Check with factory to make sure this recovery will not cause any scaling problems
with your feedwater.
• 4” diameter model no. M-T4040AHF. Vessel model: PV4040SSAW-316

WP440L-Series Reverse Osmosis System
Installation Instructions and User Manual
www.neptronic.com
Page | - 6 -
Design Assumptions
• Systems rated at: 77°F (25°C) using 1000 PPM sodium chloride solution operating at 200 psi pressure.
• Minimum feed pressure to RO System: 40 PSI. System capacity changes significantly with water temperature. For
higher TDS a water analysis must be supplied and could result in modifications to the system.
• Chlorine must be removed if present in feed water prior to RO with a carbon filter or with chemical injection.
• Water must be pretreated with a softener or antiscalant injection to avoid scaling the membranes.
• Feed water turbidity: Less than 1 NTU; Feed water silt density index (SDI): 3 maximum. If exceeded, pretreatment with
media filter recommended. All pretreatment equipment and SDI test kits are available from Applied Membranes.
• Capacity Basis: 24 hrs/day.
Design Notes
1. Pump flow/Feed flow: The pump has been designed to include recycle flow (if any) coming back to the pump inlet
from the concentrate stream based on desired recovery. The sum of permeate flow, concentrate flow and recycle flow
(if any) will equal the pump design flow.
2. Permeate flow: Indicates design flow rate from RO membranes as product water for use.
3. Concentrate flow: Water flowing to the drain. Concentrate flow is critical for proper system operation. For proper
concentrate flows, refer to the system design information on pages 3-4.
4. Recycle flow: Flow stream that returns from the concentrate line back to the pump intake, rather than to the drain.
Note 1: Permeate flow should not exceed recommended flow.
Note 2: System pressure is a variable. It is important to adjust the pressure to get the correct
permeate and concentrate flows. The exact value of the pressure is not important.
Note 3: Permeate flow will increase at higher temperature.
General Information and Safety
DISCLAIMER: The information contained in this document is subject to change without notice. Applied Membranes,
Inc. shall not be liable for technical or editorial omissions made herein; nor for incidental or consequential damages
resulting from the furnishing, performance, or use of this material.
POWER CONNECTIONS:
•Use proper wiring and connection methods to satisfy local electrical codes.
•Connect this unit to a properly grounded connection in accordance with the National Electrical Code.
•Ensure that the ground wire or ground prong is connected to the power plug.
•Do not the use extension cord or an adapter without proper consideration.
WARNING: Risk of electric shock. Disconnect the appliance from electric supply before
commencing servicing.
WARNING: Do not make any alteration or modification in the wiring or plumbing of the system.
This can result in damage to the system and cause injury to operators or users.
WARNING: Flush the system for at least 30 minutes before use to remove all chemicals present.

WP440L-Series Reverse Osmosis System
Installation Instructions and User Manual
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Page | - 7 -
CAUTION: Chlorine will damage the membranes. Chlorine must be removed from the feed
stream before entering the system.
CAUTION: Never let the system freeze. Freezing can damage the membrane and plumbing.
System Installation
Location
Select a location for the RO system with adequate clearance from walls and other equipment to enable servicing of the
pump / motor assemblies, membranes, cartridge prefilter and other serviceable components. Allow at least four (4) feet of
clearance at the top end of the membrane housings for future membrane replacement.
The unit must be located near a drain able to accommodate up to 10 GPM. This is in addition to any other equipment
sharing the drain.
A grounded power supply of the appropriate voltage matching your system model’s voltage with 15A fuse protection and a
local disconnect switch is required.
CAUTION: The system must not be located near any corrosive chemicals, or in an area where
the temperature may exceed 113°F (45°C).
WARNING: The system must be properly grounded to avoid injury from electrical shock.

WP440L-Series Reverse Osmosis System
Installation Instructions and User Manual
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Page | - 8 -
Plumbing
Refer to the P&ID on page 35 for further information.
Plumbing Installation must conform to Local and National Codes.
Any installation work must be carried out by suitably qualified personnel.
CAUTION: This unit produces high quality water which can cause corrosion or leaching of
the plumbing following the system.
Use only plumbing components of inert material that are compatible with the application.
Copper plumbing cannot be used.
Plumbing materials can significantly contribute to the contamination of the water. Care must be exercised over the choice
of thread sealants. Teflon tape is suitable for all threaded connections in this system. Pipe dope can leach objectionable
impurities into the water and must be avoided.
Feed Water Connection
Connect the raw water supply to the inlet of the solenoid valve (P.O.C), observing the following:
•The line size shall be 3/4” or larger to minimize pressure loss.
•A manual valve may be installed on this line to shut off the water supply if it will ever be needed. Be sure that this
valve in no way restricts the water flow when it is fully open.
•Water supply minimum pressure 40 P.S.I., maximum pressure 100 P.S.I. A pressure regulator may be required.
Illustration 1 - Side View of the System

WP440L-Series Reverse Osmosis System
Installation Instructions and User Manual
www.neptronic.com
Page | - 9 -
Illustration 2 - Front View of the System
Concentrate/Reject Connection
Connect a line to the concentrate connection point on the skid (refer to illustration 2). The drain must have a minimum
capacity which meets or exceeds the concentrate output of your system. Check the Design Specification (pages 3-4) for
your model.
Permeate/Product Water Connection
Connect the product water line to the product connection point on the system (refer to illustration 2). Run this line to your
storage tank or other downstream equipment, observing the following:
•Run this line in such a manner as to minimize static head pressure in the product line.
•A check valve is recommended to prevent back flow to the RO membranes. This check valve should be installed
on the output of the product connection point.
•The product line should have no restrictions to the product flow.
•Connect the product line to a bulkhead fitting at the top of the storage tank.
CAUTION: RO Membranes will fail immediately if the product water is allowed to flow
backward into the elements. Use a check valve and ensure that there are no restrictions on
the product flow to prevent backflow.
CAUTION: The highest point of the tubing should not be higher than four feet above the top
of the RO modules, or the elements may be damaged.

WP440L-Series Reverse Osmosis System
Installation Instructions and User Manual
www.neptronic.com
Page | - 10 -
Product Water Storage Tank Level Float Installation
Note: Please read all steps of installation instructions before beginning.
Note: If using a repressurization pump, a third float should be used to turn the pump off when the tank is
empty.
1. Remove the bulkhead nut from the bulkhead fitting and place the bulkhead through the opening in the tank from
the outside, making sure the bulkhead gasket is on the outside of the tank. Loosely connect the bulkhead nut and
do not tighten it.
2. Position the float tree assembly on the inside of the tank and pull the float wires through the bulkhead fitting.
Connect the float assembly tee to the bulkhead fitting by turning the bulkhead fitting from the outside of the tank.
Tighten the bulkhead nut.
CAUTION: Do not tighten by turning the float assembly inside the tank, float damage can occur.
Tighten only by turning the bulkhead fitting from the outside of the tank.
3. Position the electrical conduit elbow on the outside of the tank and pull the float wires into the conduit elbow.
Thread onto the bulkhead fitting.
4. Install SO cord (supplied by customer) through the strain relief fitting. Make sure enough wire is run into the
conduit fitting.
5. Connect the wires from the SO cord to the float switch wires with customer supplied wire nuts; refer illustration 3
and replace cover.
Note: It is recommended to test the wiring by placing an OHM meter on the connections testing for
possible short or ground. All electrical connections shall be in accordance with the NESC guidelines and
as dictated by local authorities holding proper jurisdiction for local/state and or by U.B.C., and U.M.C.
guidelines for all mechanical means.
6. Run the SO cord to the RO control panel (detailed instructions in the Electrical Connections on page 11).
Illustration 3 - Float Tree Assembly